Enhanced object-feeder pre-processing system

ABSTRACT

In some embodiments, a system and/or method includes pre-processing objects (such as, e.g., mail or other thin-objects) that are delivered to an object feeder. Various embodiments disclosed herein can have various advantages, such as enhancing processing, improving ergonomics and/or other advantages.

BACKGROUND OF THE INVENTION

[0001] 1. Field of the Invention

[0002] The present invention relates generally to, among, other things, systems for handling mail (including, e.g., flats, envelopes, letters, postcards and/or other mail) and/or other objects, and certain preferred embodiments relate, more particularly, to automated systems for pre-processing mail flats handled by mail flats sorting systems.

[0003] 2. Background Discussion

[0004] Currently, a variety of systems are used for the handling of objects, such as, e.g., thin objects like mail flats and/or other mail. For example, the United States Postal Service (USPS) uses various systems to facilitate and enhance the handling of mail flats.

[0005] For example, some illustrative mail processing systems are illustrated in U.S. Pat. No. 6,443,311 (the '311 patent), assigned to Northrop Grumman Corporation, entitled Flats Bundle Collator, the disclosure of which is incorporated herein by reference in its entirety as though recited herein in full.

[0006] As another example, one illustrative mail processing system is the AFSM100™ flats sorting system built by Northrop Grumman Corporation and Rapistan Systems and used by the USPS. The AFSM100 flats sorting machine is a mail sorting system that can process, e.g., large pieces of flat mail, such as for example magazines, in large volumes. Each AFSM100 system has three mail-feeding units.

[0007] In some of these existing mail processing systems, feeders are used to deliver mail into the systems for processing. In some illustrative and non-limiting examples, these feeders include a delivery portion and a destacking (e.g., singulating) portion. In such systems, mail is typically placed onto the delivery portion and delivered to the destacking portion. In these example systems, the mail pieces are usually delivered to a sorting section in pieces (e.g., usually having a fixed gap and/or a fixed pitch).

[0008] In such systems, operators typically load (such as, e.g., manually from mail storage hampers) the mail to be processed onto the delivery portion at the beginning of the operation. The operators usually continue to load the mail while the system processes the mail.

[0009] In modern-day mail processing environments, sorting and other systems are running faster and longer than in the past. Among other things, this can increase the burden upon the operators who feed and/or operate the systems. In many instances, the performance of mail processing equipment is increasingly dependant upon an operator's capacity to support the system.

[0010] Therefore, a need exists for a pre-processing system that can overcome, among other things, the above and/or other problems with existing systems. SUMMARY OF THE PREFERRED EMBODIMENTS

[0011] Various embodiments of the present invention can significantly improve upon existing systems and methods. In some preferred embodiments of the present invention, one or more of the above and/or other problems with existing systems can be overcome.

[0012] According to some embodiments, a method for pre-processing mail delivered to at least one mail feeder having a conveyor from which mail is fed to a downstream system includes:

[0013] a) having at least one preparation operator place non-bundled mail on a carrier; b) delivering the carrier via the delivery system to the feeder without requiring an operator to lift the carrier; and c) transferring mail from the carrier to the conveyor of the feeder. Preferably, the transferring mail includes having the feeder operator laterally move mail to the conveyor of the feeder. In some embodiments, the method further includes providing the mail as mail flats. In some embodiments, the method further includes delivering carriers from a plurality of preparation operator locations to a common supply, and delivering the carriers from the common supply to a plurality of feed operator locations proximate respective mail feeders. In some embodiments, the delivering includes delivering the carriers via the delivery system along a path that includes a lateral component such that the carrier is moved, at least in part, laterally and/or delivering the carriers via the delivery system along a path that includes a generally vertical component such that the carrier is moved, at least in part, generally vertically.

[0014] According to other embodiments, a method for pre-processing mail delivered to at least one mail feeder having a conveyor from which mail is fed into a system includes: a) de-bundling mail at at least one preparation operator location; b) placing the de-bundled mail upon at least one mail carrier; and c) delivering the at least one mail carrier to at least one mail feeder via a delivery system that permits egress of a feed operator around a periphery of each of the at least one mail feeder. In some embodiments, the delivery system includes a conveyor and a movable platform. In some embodiments, the movable platform is movable between a position adjacent the conveyor and a position adjacent the feeder.

[0015] According to other embodiments, a method for pre-processing and delivering objects to an object-feeder, comprising: a) loading objects onto a plurality of carriers; b) conveying the carriers with a supply conveyor towards an object-feeder; c) transporting at least one of the carriers from the conveyor toward the feeder upon a reciprocated transporter; d) after transporting, transferring objects from the at least one carrier to the feeder; e) after transferring, placing the at least one carrier upon a return conveyor.

[0016] According to other embodiments, a mail handling system includes: a) a feeder for feeding mail; b) a plurality of mail carriers; c) a transporter upon which at least one of the mail carriers can be placed; d) the transporter including a platform that is movable along a path from a location proximate the feeder to a location distal from the feeder so as to permit egress of a feed operator around a periphery of the feeder.

[0017] According to other embodiments, a thin-object handling system includes: a) a feeder for feeding thin-objects; b) a plurality of carriers carrying a plurality of the thin-objects; c) a conveyor for conveying the carriers toward the feeder; d) a transporter arranged to transport at least one of the carriers from the conveyor toward the feeder, the transporter being movable to permit egress of a feed operator around a periphery of the feeder. In the preferred embodiments, the thin objects include mail.

[0018] The above and/or other aspects, features and/or advantages of various embodiments will be further appreciated in view of the following description in conjunction with the accompanying figures. Various embodiments can include and/or exclude different aspects, features and/or advantages. In addition, various embodiments can combine one or more aspect or feature from other embodiments. The descriptions of aspects, features and/or advantages of particular embodiments should not be construed as limiting other embodiments or the claims.

BRIEF DESCRIPTION OF THE DRAWINGS

[0019] The accompanying figures are provided by way of example, without limiting the broad scope of the invention or various other embodiments. In the figures, like reference numerals designate like or similar parts, wherein:

[0020]FIG. 1 is an elevational view of components of a system according to some preferred embodiments of the invention;

[0021]FIG. 2 is an enlarged elevational view of, among other things, preparation operation components of a system similar to that shown in FIG. 1;

[0022]FIG. 3 is a schematic diagram depicting components that can be employed to control the operation of a supply conveyor in some illustrative embodiments of the invention;

[0023]FIG. 4 is an enlarged elevational view of, among other things, feeder operation components of a system similar to that shown in FIG. 1;

[0024]FIG. 5 is a schematic top elevational view of a plurality of systems according to some illustrative embodiments of the invention;

[0025]FIG. 6 is a schematic top view of a plurality of systems according to some illustrative embodiments of the invention;

[0026]FIG. 7 is a schematic top view of a plurality of systems according to some illustrative embodiments of the invention;

[0027]FIG. 8 is an elevational side view of two carriers that may be employed in some illustrative embodiments of the invention;

[0028]FIG. 9 is an elevational view of a system according to some preferred embodiments of the invention having common supply lines between preparation operators and feeder operators; and

[0029]FIG. 10 is an elevational view of a system according to the most preferred embodiments of the invention wherein carriers are moved generally vertically to-and/or-from a feeder or other system.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0030] Various embodiments of the present invention can be employed in a variety of systems and devices. In some non-limiting examples, embodiments of the present invention can be employed within systems similar to that shown in the '311 patent, such as, e.g., to enhance processing at the feeder 10 shown in FIG. 1 of the '311 patent. Additionally, various embodiments of the present invention can be employed, in other non-limiting examples, for use with an AFSM100™ flats sorting system.

[0031] While the preferred embodiments can be used to process mail (including, for example, boxes, flats, envelopes, letters, postcards and/or other mail), and the most preferred embodiments can be used to process mail flats, various embodiments can also or can alternatively be used to process other objects (such as, e.g., objects of any configuration). In the more preferred embodiments, the objects comprise thin objects, such as, e.g., sheets, boards, panels, magazines, paper goods and/or other thin objects. In some preferred embodiments, mail flats are handled. In certain preferred embodiments, a given system may handle a multitude of thin objects (such as, e.g., mail flats) of different sizes and/or shapes at a given time. However, the thin objects preferably fall within a predetermined range of characteristics.

[0032] For example, in certain preferred embodiments, the system can be adapted to handle mail flats having one or more of the following characteristics. In some embodiments, each flat is generally rectangular and: a) has a height of between about 12 inches and 5 inches; b) has a length of between about 15 inches and 6 inches long; and/or c) has a thickness of between about 0.75 inches and 0.009 inches. Moreover, in some embodiments, each flat is also within one or more of the following weight limits: a) under about 13 ounces (e.g., for first-class mail); b) under about 16 ounces (e.g., for standard mail); and/or c) under about 20 ounces (e.g., for periodicals and bound printed matter). Moreover, in some embodiments, each flat also meets various postal service (e.g., USPS) standards related to “turning ability” and/or “deflection.” While some preferred embodiments involve the handling of flats having characteristics as discussed herein, numerous other embodiments can be employed having various other flat configurations or specifications, such as, e.g., that disclosed in the '311 patent. The foregoing illustrative embodiments do not limit the broad applicability of the invention to mail flats and/or other objects or materials having other characteristics, which may vary widely depending on the particular circumstances.

[0033] In some illustrative embodiments, a pre-processing system can be provided so as to service one or more AFSM100™ system or other system(s) and can include, for example, one or more, preferably all, of the following: a full carrier supply conveyor 10; an empty carrier return conveyor 20; a movable container tilter 30; a fixed assist platform 40; a transfer slide 50; and/or a plurality of mail carriers 60.

[0034] In illustrative embodiments, as shown in FIGS. 1 and 2, bundled flat mail can be de-bundled and prepared directly from hampers 30H into mail carriers 60 at the inlet end 10A of a supply conveyor 10. The full carriers 60 can then be queued and transported to a fixed assist platform 40 located between the conveyor 10 and the feeder 100. The full carriers 60 can be moved (e.g., using the fixed assist platform 40) onto a receiving region 110 at an inlet end of the feeder. The feeder operator OpF preferably unloads the flats F into the feeder 100 and then places the empty carrier 60 onto the empty carrier return conveyor 20.

[0035] While some embodiments can be used, e.g., with feeders that feed mail, various other embodiments can be used with feeders that feed other objects or materials. The terminology feeder includes, as per Webster's II New Riverside Dictionary, “[a] device that supplies . . . material” and is not limited to any particular form of feeding or to any particular object fed.

[0036] Supply Conveyor:

[0037] In some illustrative embodiments, a full carrier supply conveyor 10 can include a powered-roller, zone-accumulation conveyor to queue and transport full carriers from a preparation operator OpP loading zone (see, e.g., zone Z1 in FIG. 3 at the inlet end 10A of the conveyor) to the fixed assist platform 40. The conveyor 10 can include, e.g., a plurality of powered rollers 11. In other embodiments, any other conveyor(s) can be employed, such as, e.g., one or more rotary belt(s), one or more pusher(s), one or more moving platform(s) and/or any other appropriate conveyor(s). The downstream end of the supply conveyor can be located adjacent to a location to which delivery is desired, such as adjacent a feeder 100 (such as, e.g., an AFSM100 feeder). Preferably, there is a distance Dl of at least about a few feet between the feeder or the like and the discharge end of the conveyor (e.g., to enable an operator to freely pass there-between). This distance D1 can be, in some illustrative embodiments, between about 3 to 5 feet, and, in one illustrative embodiment, about four feet, or, more preferably, about 46 inches.

[0038] In some illustrative embodiments, the supply conveyor is sufficiently long to handle a multitude of carriers at a given time, such as, e.g., 2 or more carriers, or, more preferably, 3 or more carriers, or, more preferably, 5 or more carriers. In some illustrative examples, the conveyor can have a length DS of between about 5 and 15 feet long. In some illustrative examples, the conveyor can be between about 1 and 3 feet wide. In one illustrative embodiment, the conveyor is about 10 feet long, about 2 feet wide and can store 5 carriers at a given time. In some illustrative embodiments, the conveyor can run at a rate of between about 25 and 75 feet per minute (FPM), and, in one illustrative example, it can run at about 50 FPM. In some illustrative embodiments, the supply conveyor is divided into five two-foot long zones, such as, e.g., zones Z1-Z5 depicted in FIG. 3.

[0039] In some embodiments that have a plurality of “zones” associated with the conveyor 10, as shown in FIG. 3, detectors or sensors 18, such as, e.g., photosensors or photoeyes, can be located, for example, at a downstream edge of each zone to detect the presence of carriers thereon. The detectors 18 can, e.g., output signals identifying the presence and/or absence of carriers at particular locations. In some embodiments, as shown in FIG. 3, a controller, such as e.g., a computer, a processor or the like can be used to selectively activate appropriate rollers via one or more roller drive mechanism(s). In this manner, for example, rollers within a particular zone can be automatically activated to convey carriers. For instance, full carriers can be automatically moved forward into empty downstream zones, such as, e.g., as they are processed.

[0040] Preferably, a position detector or sensor 12, a pop-up stop 13 and an index push button 14 are located proximate the discharge end 10B of the supply conveyor. The pop-up stop 13 is preferably normally raised so as to prevent carriers 60 from moving off the end of the supply conveyor 10 when the platform 40 is not in a position adjacent thereto. Preferably, when the fixed assist platform 40 is moved into a position adjacent the discharge end of the supply conveyor, a coupling mechanism prevents the platform 40 from shifting. The position sensor 12 preferably verifies that the platform is in position and locked. Preferably, upon such verification, the pop-up stop 13 is automatically controlled so as to lower to allow carriers 60 to be delivered off of the supply conveyor. The control can be effected in a variety of ways, such as, e.g., using a solenoid to move the pop-up stop and providing an actuating current to the solenoid in response to a detection by the sensor 12. In some embodiments, the control can utilize one or more controller, such as, e.g., the controller shown in FIG. 3.

[0041] Preferably, the index push button 14 causes a full carrier 60 to be moved from a downstream zone of the conveyor 10 onto the platform 40. The index push button 14 can, e.g., include a button that is depressed by an operator (e.g., manually or the like). In some embodiments, pushing the button 14 will cause the pop up stop 13 to retract and will cause at least some rollers 11 of the conveyor to move the carrier forward.

[0042] Preferably, the operator is responsible for releasing the coupling mechanism between the platform 40 and the conveyor after the carrier has been safely transferred. This latter feature can help to ensure that the platform 40 does not separate from the supply conveyor while a full carrier is being transferred to the platform 40. Once the assist platform 40 and the supply conveyor 10 are decoupled, the pop-up stop 13 is preferably automatically actuated to pop-up into a blocking position.

[0043] Preferably, another index push button 15 and a fixed stop 16 are located at the inlet end 10A of the supply conveyor 10. As discussed above, the preparation operator OpP fills empty carriers 60 at an upstream loading zone. Preferably, the fixed stop 16 prevents the carriers from moving off the inlet end of the conveyor. The operator OpP can preferably depress the index push button 15 to move a full carrier from the upstream loading zone Z1 forward via the conveyor 10. For instance, the index push button 15 preferably causes certain rollers 11 (e.g., within zone Z1 in the example shown in FIG. 3) to rotate and move a carrier forward. Preferably, an emergency stop pull cord 17 runs substantially along the length of the supply conveyor to enable the conveyor to be manually stopped, such as, e.g., by being manually actuated (e.g., pulled) to stop the conveyor 10 during some circumstances.

[0044] While the supply conveyor includes powered rollers in some illustrative embodiments, one or more other conveyor(s) could be employed in various other embodiments. For example, one or more conveyor belt(s) and/or other conveyor can be included. The terminology “conveyor” used in this application includes any mechanism by which carriers can be moved, such as, e.g., one or more rotary belt(s), one or more pusher(s), one or more moving platform(s) and/or any other appropriate conveyor(s). In preferred embodiments, such conveyor(s) is configured to have differentiated carrier movement between a plurality of zones along the conveyors.

[0045] Return Conveyor:

[0046] Preferably, an empty carrier return conveyor 20 is provided. In preferred embodiments, the return conveyor 20 can be substantially similar to the supply conveyor 10, but usable to return empty carriers. In one illustrative embodiment, the return conveyor 20 can be similar to the supply conveyor 10, such as, e.g., in one illustrative example, about 10 feet long and about 2 feet wide. As with the supply conveyor 10, the dimensions of the return conveyor 20 can vary based on circumstances. Preferably, the return conveyor 20 is a powered-roller, low-pressure accumulation conveyor. Preferably, the conveyor 20 or a substantial portion of the conveyor 20 is located below the supply conveyor 10. In preferred embodiments, the conveyor 20 is used to queue and transport empty carriers to the preparation operator OpP.

[0047] As with the supply conveyor 10, the return conveyor 20, as would be understood based on this disclosure, can include any appropriate conveyor(s). Moreover, in some embodiments, the operation of the return conveyor could also be controlled via a controller or the like, such as, e.g., via the same controller depicted in FIG. 3.

[0048] Hamper:

[0049] Preferably, a hamper 30H is provided for containing mail flats. In some embodiments, a hamper 30H can include an open-top container having a bottom and four side walls as illustrated, e.g., in FIGS. 1 and 2. In some illustrative and non-limiting embodiments, a hamper tilter 30 is provided for manipulating the hamper 30H. In some illustrative embodiments, a SOUTHWORTH PORTABLE POSTAL CONTAINER TILTER (such as, e.g., model PTU-2DC) can be used. These latter tilters have been used by the USPS for ergonomic processing of certain material transport equipment. In some instances, a tilting force can be applied to enable tilting of the hamper 30H to an ergonomic position. In some instances, the tilter can include a hydraulic power train with, e.g., a DC motor and a hydraulic pump. The container tilter, in some embodiments, can have a capacity of over 1,000 pounds (lbs) and preferably at least about 2000 lbs. Preferably, it is capable of rotating plastic and/or canvas hampers, wiretainers and/or Gaylords more than about 60 degrees, and, preferably, up to at least about 80-90 degrees. In one illustrative example, the tilter is supported by rollers (e.g., about 3 to 3½ inches in diameter) on a front side and swivel casters (e.g., about 6 inches in diameter) on a rear side.

[0050] Transporter (e.g., Fixed Assist Platform):

[0051] In preferred embodiments, a transporter is provided that transports carriers to the feeder. Preferably, the transporter is configured to transport at least one full carrier from the conveyor to the feeder. The terminology transporter includes any device that transports or conveys from one place to another. In preferred embodiments, the transporter is movable to permit egress of a feed operator around a periphery of the feeder. In various embodiments, any form of transporter can be employed, such as, e.g., movable platform(s), movable drawer(s), trolley(s), wheeled support(s), vehicle(s), conveyor(s) and/or other appropriate transporter device(s). In some preferred embodiments, the transporter is reciprocatable. In some preferred embodiments, the transporter can be reciprocated along a generally constant path of travel (e.g., along a track or the like), while in other embodiments the reciprocation can involve a generally back-and-forth movement between two locations that does not follow a particular path of travel.

[0052] In some embodiments, a delivery system that delivers carriers to a feeder can include one or more transporter and/or one or more conveyor (such as, e.g., supply conveyor 10). The terminology delivery system includes any system that delivers objects and encompasses one or more, e.g., transporter(s), conveyor(s) and/or the like.

[0053] In some preferred embodiments, the transporter can include a platform, such as, e.g., fixed assist platform 40, that facilitates transport to the feeder 100. The terminology platform encompasses any structure that can support a carrier. In some embodiments, the platform can include a generally flat surface, while in other embodiments the platform can include a variety of other configurations. In addition, a platform can include a plurality of separate portions that together support one or more carrier. In the illustrative embodiment shown in FIG. 1, the platform 40 is supported via a frame 41 having at least one generally upright support member 43 (two members 43 are shown in the illustrative embodiment shown in FIG. 1) and at least one transverse member 42 (two members 42 are shown in the illustrative embodiment shown in FIG. 1). In an illustrative embodiment, the platform 40 is supported via at least one hanging support member 44 (two members 44 are shown in the illustrative embodiment shown in FIG. 1). Preferably, each support member(s) is movably attached to at least one transverse member 42 via a linearly movable attachment mechanism 45 (such as, e.g., via linear bearings, rollers and/or other suitable lateral moving mechanisms as would be apparent based on this disclosure). Preferably, the linear bearings or other moving mechanisms are configured to allow the platform 40 to be moved along an axis that is substantially parallel to an axis along the supply conveyor (e.g., at a discharge end thereof) and connecting the supply conveyor 10 and the feeder 100. Moreover, the direction of travel of the platform 40 is preferably parallel to the direction of travel of the roller conveying surface of the supply conveyor 10.

[0054] In some preferred embodiments, the platform 40 is manually positioned along the frame 41, such as by manually pushing the platform so as to slide it laterally across the frame 41. Thus, in some preferred embodiments, the platform 40 is not moved via a power source. However, in various embodiments, a motor and/or other moving mechanism can be used to facilitate and/or to effect movement of the platform 40 across the frame 41.

[0055] In preferred embodiments, the fixed assist platform 40 is used to transport full carriers 60 from a discharge end of the supply conveyor 10 to an upstream end of the feeder 100. In preferred embodiments, the fixed assist platform 40 includes a plurality of non-powered conveyor rollers for facilitating movement of the carriers 60 to and from the assist platform 40. In some illustrative embodiments, the platform 40 can include a non-powered roller conveying surface that is between about 1-2 feet long, and, more preferably, about 16 inches long, and about 1-3 feet wide, and, more preferably, about 24 inches wide. In some illustrative embodiments, the platform is moved between about 3-5 feet, and, more preferably, about 4 feet, and, in some illustrative embodiments, about 46 inches between a first functional position 40P1 adjacent the supply conveyor 10 and a second functional position 40P2 adjacent the feeder 100, such as shown in FIG. 5.

[0056] In preferred embodiments, these two functional positions of the platform are at each end of its effective travel. In the first position 40P1, an inlet end of the platform 40 is preferably located adjacent a discharge end 10B of the supply conveyor 10. In the second position 40P2, the platform 40 is preferably located adjacent to the feeder 100, such as, e.g., upon a region 110, such that a full carrier located on the conveying surface of the platform can be easily unloaded into the feeder 100.

[0057] In some illustrative embodiments, a supporting frame structure and/or other supporting structure (such as, e.g., the overhead type frame 41 shown in the illustrative embodiment) is configured to facilitate at least one, preferably both, of the following two criteria discussed below.

[0058] For the first preferred criteria, egresses to and/or around a feeder 100 or the like are preferably maintained so as to be sufficiently large (such as, e.g., egresses are preferably substantially the same as that with an existing system, such as in an existing AFSM100 system). In some illustrative embodiments, such as shown in FIG. 5, full carriers 60 can be moved from a discharge end 10B of the supply queue of the supply conveyor 10 to a desirable unload position at the inlet of the feeder 100 without blocking feeder operator egress 40E to, e.g., a backside of the feeder. Preferably, the fixed assist platform 40 is usually positioned either at a supply queue position 40P1 or at a feeder position 40P2, such as depicted in FIG. 5. In the illustrative embodiment shown in FIG. 5, when the fixed assist platform 40 is positioned at location 40P1 adjacent the discharge end of the supply conveyor, there is about a 30 inch aisle D2 between the feeder 100A and a discharge end of fixed assist platform. In the illustrative embodiment shown in FIG. 5, when the fixed assist platform 40 is positioned at a location 40P2 adjacent the feeder, there is about a 46 inch aisle D1 between the feeder 100C and the discharge end of the supply conveyor. While these dimensions are selected in some preferred embodiments, dimensions in other embodiments can vary depending on circumstances. As merely some non-limiting examples, these dimensions can be changed plus-or-minus 10% in some embodiments, or plus-or-minus 25% in some other embodiments, or plus-or-minus 50% in some other embodiments.

[0059] With respect to the second preferred criteria, the feeder operator is preferably allowed substantially full access to a side of the carrier without, e.g., a need for reaching in a non-ergonomic manner. For instance, the feeder operator is preferably able to stand facing a side of the carrier substantially without obstructions between the operator OpF and the prepared mail (such as, e.g. shown at operator position OpF/40 in FIG. 5). Among other things, substantially complete access to the carrier 60 and/or the prepared mail can help to ensure an ergonomic loading of the feeder 100.

[0060] In some preferred embodiments, the fixed assist system preferably includes one or more, preferably all, of the following three control features.

[0061] A first control feature preferably includes the use of non-powered rollers that are mechanically limited so as rotate in only one direction (preferably, in substantially the same direction of travel as the supply conveyor 10). Among other things, this can enable the full carriers to be conveyed onto the platform 40, while inhibiting them from backing off the platform when moved toward the feeder 100. Preferably, the rollers are also lagged with a high friction rubber sleeve (such as, e.g., to inhibit movement, such as sliding, of the carriers 60 upon the platform independent of the rotation of the platform rollers).

[0062] A second control feature preferably includes providing a fixed stop at the downstream end of the platform so that full carriers are inhibited from moving forward off the downstream end of the platform. Among other things, combining a fixed platform stop with a mechanically limited roller rotation (such as, e.g., according to the first control feature) can effectively trap a full carrier, such as, e.g., when it is moved onto the platform.

[0063] A third control feature preferably includes that the platform automatically couples (e.g., locks and/or latches) to, e.g., the supply conveyor 10 and/or to a fixed support proximate thereto when it is moved into the platform loading position 40P1 adjacent the discharge of the supply conveyor. Any appropriate coupling mechanism (e.g., any appropriate lock and/or latch mechanism) can be used. As merely one example, as shown schematically within the dashed circle in FIG. 1, a coupling mechanism 40C can be provided that includes a locking lever 40L having a camming surface 40S that can cause the lever 40L to rotate and/or move in a generally vertical direction by a camming action over a fixed locking block 40B (wherein, the lever 40L and the block 40B are fixed relative to a respective one or the other of the platform 40 and the conveyor 10).

[0064] In preferred embodiments, a transfer slide 50 is also provided on an upstream end of the feeder 100. In some preferred embodiments, wherein an existing system, such as an AFSM100 system, is being upgraded, an existing feeder may be retrofitted with such a transfer slide. In some preferred embodiments, the elevation and/or the angle of the transfer slide is set to allow the feeder operator OpF to easily slide objects, such as, e.g., handfuls of mail flats, from a carrier onto the feeder (e.g., onto a conveyor belt of the feeder). In preferred embodiments, the objects (e.g., mail flats) do not have to be lifted to be loaded into the feeder. Among other things, sliding the flats can allow the operator to handle larger amounts of objects (e.g., larger handfuls of mail flats) and/or can reduce the number of operator loading cycles. In some illustrative and non-limiting embodiments, the transfer slide can have a length of about 12 inches, a height of about 4 inches, and be inclined at an angle of about 15 degrees.

[0065] Carriers:

[0066] In various embodiments, the object carriers 60 can have a variety of constructions (e.g., depending on the characteristics of the objects, such as, e.g., mail flats, to be carried). In some preferred embodiments, the carriers are made with plastics material. In some preferred embodiments, the carriers are formed by a molding process, such as, e.g., by injection molding. In some preferred embodiments, the carrier size is preferably selected so as to fit a single carrier upon the platform 40 (such as, e.g., with a limited amount of extra space on the platform). In some preferred embodiments, the carriers are constructed so as to weigh less than about 10 pounds, and, more preferably, less than about 8 pounds, and, more preferably, approximately 6 pounds in some illustrative embodiments. In some preferred embodiments, the carriers are adapted to support mail flats and have a capacity of holding more than one hundred mail flats, and, more preferably, more than about 150 mail flats, and, in some illustrative embodiments, approximately 170 mail flats.

[0067] In some preferred embodiments, side and bottom surfaces are canted at an angle α (such as, e.g., between about 5 and 15 degrees, and, more preferably, approximately 10 degrees) to effectively retain the prepared mail while it is transported on the supply conveyor. Preferably, two small upwardly protruding retaining edges 61 prevent the mail from sliding off the base support wall 62 of the carrier 60. In addition, the base support wall 62 is preferably generally transverse to a side support wall 63 at an angle θ (preferably, e.g., approximately 90 degrees). In preferred embodiments, the carriers are constructed so as to include thin plastic walls and, preferably, the walls 62 and 63 are reinforced with ribs 62R and 63R, respectively, as shown. In some illustrative embodiments, the carriers can have a length L of about 16 to 24 inches, and, more preferably, about 20 inches. In some illustrative embodiments, the carriers can have a width W of about 10 to 20 inches, and, more preferably, about 15 inches.

[0068] As shown schematically in the dashed line circle shown in FIG. 8, in some embodiments, an outer end 62E of the bottom support wall 62 can include an overhanging section 62L, which is configured to extend over an input edge of a transfer slide 50.

[0069] While some illustrative carrier designs have been depicted and described, various embodiments can accommodate various carrier designs. For example, various systems according to embodiments of the present invention may operate with a variety of carrier types and designs.

[0070] Operation:

[0071] In some illustrative embodiments, the operation of such embodiments may be as set forth below.

[0072] With respect to preparation and queuing, a preparation operator OpP is preferably stationed proximate an inlet end 10A of the supply conveyor 10. A hamper 30H of bundled objects (e.g., bundled mail flats) is preferably positioned adjacent to the inlet of the supply conveyor. Preferably, the hamper is located within a few feet of the conveyor 10, and, most preferably, within arms reach of the preparation operator OpP. The preparation operator preferably uses a hamper tilter 30 to manipulate the hamper 30H into an ergonomic position. During operation, the preparation operator OpP preferably retrieves empty carriers from a discharge of an empty carrier return line 20. The preparation operator preferably places the empty carriers upon the upstream zone (such as, e.g., zone Z1 shown in FIG. 3) at an inlet of the supply conveyor 10.

[0073] Preferably, the preparation operator acquires bundles of mail flats from the hamper 30H and removes the bindings that maintain the mail flats in such bundles. In some preferred embodiments, a hanging band cutter 30C (such as, e.g., shown in FIG. 9) can be provided to facilitate cutting of the bindings. After a binding is removed, the loose mail flats are preferably placed onto a carrier 60. In some preferred embodiments, the mail flats are placed with any bound edges down upon the carrier 60. The position of the hamper 30H relative to the carrier, the use of the hamper tilter, and the elevation of the carrier 60 (at a loading zone of the supply conveyor 10) are preferably arranged so as to minimize operator movement and to maximize operator ergonomics. In the embodiment shown in FIG. 6, the hamper 30H is located substantially next to the supply conveyor 10, wherein an operator OpP faces the hamper and the supply conveyor at the same time. In the embodiment shown in FIG. 7, the hamper 30H is located at an angle (e.g., generally perpendicular) to the supply conveyor 10, wherein an operator OpP can readily reach between such positions as shown. In some preferred embodiments, the operator OpP is not required to significantly walk and/or to significantly turn their body (e.g., their torso). In some preferred embodiments, the operator is not required to bend significantly, such as, e.g., in some embodiments with a lower position return conveyor, an operator merely bends once per carrier load (e.g., to retrieve an empty carrier).

[0074] Preferably, once a carrier 60 upon the loading zone of the conveyor 10 is full, the preparation operator OpP presses the index button 15. Preferably, the supply conveyor 10 is then automatically activated to move the full carrier forward into the next zone. Various forms of automatic control can be used, such as, e.g., computer control systems, processors and/or any other control to effect desired movement upon activation of the button 15 (such as, e.g., using a controller as shown in FIG. 3). The prepared carriers 60 are preferably supplied via the conveyor 10 for transportation to the fixed assist platform. If a carrier cannot be immediately transported on the fixed assist platform, it is preferably queued on the supply conveyor 10.

[0075] As shown in FIGS. 6 and 7, in some embodiments, one or more feed operators OpF can be provided with backup hampers 30HB, whereby feed operators can function as backup preparation operators and prepare objects in the event that a full carrier is not present for the feed operator. Among other things, this can help to maximize use of personnel and resources.

[0076] With respect to feeder operation, in preferred embodiments, the feeder operator manually moves the empty fixed assist platform 40 into position 40P1 at the discharge end of the supply conveyor. As discussed above, a coupling mechanism preferably automatically couples the fixed assist platform and the supply conveyor. Preferably, the feeder operator OpF then presses the indexing button 14 and waits until a full carrier is completely transported onto the fixed assist platform 40. In some embodiments, the operator can be relied upon to, in some or all instances, apply a manual force (e.g., a small or moderate manual force) to help move the carrier onto, e.g., non-powered rollers of the platform 40.

[0077] Preferably, once the carrier 60 is securely located on the fixed assist platform, the feeder operator OpF manually decouples the fixed assist platform from the supply conveyor. In preferred embodiments, the operator OpF also manually moves the platform to the carrier unload position 40P2 at the feeder 100. The feeder operator OpF preferably removes the mail from the carrier and places it into the feeder. Once all the mail has been emptied from the carrier, the feed operator OpF can, e.g., place the empty carrier onto the carrier return line.

[0078] As discussed above, the mail flats are preferably removed from the carrier and placed onto the feeder without the need for the operator to significantly lift the flats, to significantly carry the flats, to significantly reach his or her body and/or to significantly bend his or her body. Additionally, in preferred embodiments, the feed operator's need to walk and/or to turn can be significantly reduced.

[0079] Other Embodiments

[0080] In other embodiments, the various aspects, features and/or embodiments described above can be modified.

[0081] In some embodiments, for example, the fixed assist platform 40 can have a powered conveying surface. For instance, an electric motor (not shown) could also be supported via the support members 44. The motor could be, e.g., laterally moved along with the platform. Moreover, the motor could be, e.g., coupled to effect rotation of the rollers on the platform.

[0082] In other embodiments, for example, a non-manual (e.g., automatic) moving mechanism could be provided to effect and/or to facilitate movement of the fixed assist platform (such as, e.g., between positions 40P1 and 40P2), rather than, or in addition to, manually moving the platform there-between.

[0083] In other embodiments, for example, the platform 40 can be raised and/or lowered to interface with the empty carrier line 20, and/or to interface with the supply line and/or to interface with other processing equipment. In some embodiments, this raising and/or lowering action could be imparted manually. In some embodiments, this raising and/or lowering action could be imparted via a non-manual mechanism, such as via a motor-driven elevator mechanism. In some illustrative examples, the platform 40 could be movably supported upon the support member(s) 44 via a motor driven drive chain.

[0084] In other embodiments, for example, the platform 40 can have a frame and/or support structure that is supported from below, rather than from above. Furthermore, in other embodiments, for example, the platform 40 could be supported upon a frame and/or other structure that is suspended from a ceiling and/or from another structure.

[0085] In other embodiments, for example, the supply conveyor system, the empty conveyor system and/or the fixed assist platform system could be constructed so as to be movable. For instance, one or more, or all, of these systems could be fitted with wheels or casters to allow the system to be moved within a facility or the like.

[0086] In other embodiments, as shown for example in FIG. 9, a plurality of supply lines 10 could be fed by a main trunk line 10M. In the illustrative embodiment shown in FIG. 9, the main trunk line 10M can feed to the supply lines 10 via lateral (e.g., right-angle) transfer mechanisms. As also illustrated in FIG. 9, in some embodiments, a similar empty carrier return line 20M can be positioned proximate (e.g., underneath) the supply line. In some embodiments, the main trunk line 10M could be fed from a plurality of preparation workstations PW (while three workstations are shown in the illustrated embodiment, other embodiments can include any desired number of workstations), such as via lateral (e.g., right-angle) transfer mechanisms 10L. Similarly, empty carrier return or recirculation lines can be positioned proximate (e.g., underneath) the workstation lateral transfer mechanisms as shown. FIG. 9 also shows an optional flats tub supply line 10FT that can be provided in some other embodiments. For instance, a flats tub supply line could be used to supply tubs of flats from other sources, such as, for example, from postal service tray management systems (TMS), or from other sources.

[0087] Other Most Preferred Embodiments

[0088]FIG. 10 illustrates some aspects and features according to some most preferred embodiments of the invention. In the embodiments shown in FIG. 10, a generally vertical elevator 200 is provided. In preferred embodiments, the elevator 200 includes a conveyor system for moving carriers up-and-down between a supply conveyor 10M (such as, e.g., having rollers, as shown, or other conveyor mechanisms as described above) and a return conveyor 20M. In some preferred embodiments, the elevator conveyor system includes two platforms, including an upper platform 40E for conveying empty carriers 60E and a lower platform 40F for conveying full carriers 60F. In some illustrative embodiments, the platforms 40E and 40F can be mounted together so as to remain a fixed distance from one another (e.g., a distance substantially equal to the distance between the conveyors 10M and 20M). In FIG. 10, the leftmost elevator shows an empty carrier 60E and a full carrier 60F in transport together. In some instances, however, the platform 40E may be without another carrier during transport of a full carrier 60F to the feeder 100. Then, upon transfer of the objects to the feeder, the emptied carrier can be placed upon the platform 40E. The elevator can then raise the platforms such that the empty carrier 60E is laterally discharged to the conveyor 20M, and, such that a full carrier is laterally moved to the platform 40F. Then, the elevator can lower the new full carrier to continue the process. In other embodiments, the platforms 40E and 40F can be controlled so as to move independently from one another. In other embodiments, the platforms could be located adjacent one another (e.g., with a modified elevator 200 having, e.g., plural elevator shafts) so that upward and/or downward movement may occur independently of one another. However, mounting both platforms to move along a path having a common axis can enhance space saving characteristics and improve egress around the feeder 100.

[0089] In the illustrative embodiment shown in FIG. 10, the elevator 200 includes a support frame 41. Preferably, the elevator has transparent and/or translucent walls or windows (such as, e.g., made of glass, plexiglass, plastic or the like) to enable the interior to be viewed during operation. Preferably, the conveyors 10M and 20M include lateral guide rails (shown), support edges or the like to help retain the carriers thereon. Preferably, carriers 60E and/or 60F are delivered between the conveyors 10M and/or 20M via lateral transfer mechanisms, such as discussed above. Additionally, in some preferred embodiments, sensors or detectors, such as discussed above, can be used to facilitate control of the system based on carrier positioning. For instance, the lateral transfer mechanisms can be controlled based on carrier presence within the elevators 200 and the like in some embodiments.

[0090] In some illustrative embodiments, the platforms 40E and 40F can include mechanisms to facilitate transfer to and/or from the platform. For instance, in some embodiments, the platforms can include powered rollers or powered casters to facilitate movement along one or two axes (e.g., parallel to the platform). In this manner, the carriers can easily be transferred to and/or from the platforms (such as, e.g., at their upper positions proximate the conveyors 10M and 20M and/or at their lower positions proximate the feeder operator OpF). In some preferred embodiments, the front of the elevators 200 in front of the operator OpF will include openings, doors, gates or the like to enable access to the carriers on the platforms 40E and/or 40F by the operator OpF. In some preferred embodiments, fixed and/or pop-up stops can be used to limit movement of the carriers from the elevator until desired by the operator OpF.

[0091] In some preferred embodiments, the conveyors 10M and 20M shown in FIG. 10 can extend to another elevator (not shown) similar to the elevators 200. This latter elevator can then assist in the transfer of the carriers to-and/or-from one or more preparation operator location. For example, this elevator can then transfer the carriers to additional conveyors and structure similar to that shown to the left side of the dashed line A-A in FIG. 9, similar to that shown to the right side of the dashed line B-B in FIG. 2, or to other appropriate conveyors and/or structures as would be understood based on this disclosure. In some preferred embodiments, rather than maintaining the supply conveyor in a lower position as shown in FIG. 10 when it reaches the preparation operator OpP, the conveyors would be adapted to allow the preparation operator OpP to place carriers on a supply conveyor 10 at an elevation similar to that shown in FIGS. 2 and 9 (such as, e.g., by ramping the conveyors 10 and/or 20 upward and/or downward to a desired level, such as, e.g., to positions similar to that shown in FIGS. 2 and 9).

[0092] Various aspects of the embodiments described above with reference to FIGS. 1-9 can be employed in the embodiments depicted in FIG. 10.

[0093] In some illustrative embodiments, the feeder 100 can include a conveyor belt 120 extending along a substantial portion of a top surface thereof and a pusher 130. The pusher 130 can be controlled so as to follow the conveyor belt 120 so as to act as a kind of “book end” for thin objects, such as, e.g., mail flats, placed on their narrow ends in a side-by-side manner at a right side of the pusher 130 (with reference to FIG. 10). The conveyor belt 120 and the pusher 130 can move flats F laterally into the feeder for delivery into the mail processing system 300. In some embodiments, the pusher 130 is mounted such that, when desired it can be manually grasped at handle 130H and raised upward and moved back to a left side of the conveyor belt 120 to support additional flats. Preferably, the pusher 130 is disengaged from its associated drive mechanism upon being lifted and is re-engaged with its associated drive mechanism upon being lowered back toward the conveyor belt 120.

[0094] While illustrative embodiments of the invention have been described herein, the present invention is not limited to the various preferred embodiments described herein, but includes any and all embodiments having modifications, omissions, combinations (e.g., of aspects across various embodiments), adaptations and/or alterations as would be appreciated by those in the art based on the present disclosure. The limitations in the claims are to be interpreted broadly based the language employed in the claims and not limited to examples described in the present specification or during the prosecution of the application, which examples are to be construed as non-exclusive. For example, in the present disclosure, the term “preferably” is non-exclusive and means “preferably, but not limited to.” Means-plus-function or step-plus-function limitations will only be employed where for a specific claim limitation all of the following conditions are present in that limitation: a) “means for” or “step for” is expressly recited; b) a corresponding function is expressly recited; and c) structure, material or acts that support that structure or step are not recited. 

What is claimed is:
 1. A method for pre-processing mail delivered to at least one mail feeder having a conveyor from which mail is fed to a downstream system, comprising: a) having at least one preparation operator place non-bundled mail on a carrier; b) delivering said carrier via said delivery system to the feeder without requiring an operator to lift said carrier; and c) transferring mail from said carrier to the conveyer of the feeder.
 2. The method of claim 1, wherein said transferring mail includes having the feeder operator laterally move mail to the conveyor of the feeder.
 3. The method of claim 1, further including providing said mail as mail flats.
 4. The method of claim 1, further including delivering carriers from a plurality of preparation operator locations to a common supply, and delivering said carriers from said common supply to a plurality of feed operator locations proximate respective mail feeders.
 5. The method of claim 1, wherein said delivering includes delivering said carriers via said delivery system along a path that includes a lateral component such that said carrier is moved, at least in part, laterally.
 6. The method of claim 1, wherein said delivering includes delivering said carriers via said delivery system along a path that includes a generally vertical component such that said carrier is moved, at least in part, generally vertically.
 7. The method of claim 1, wherein said delivery system includes a conveyor.
 8. The method of claim 1, wherein said delivery system includes a movable platform.
 9. The method of claim 1, wherein said delivery system includes a conveyor and a movable platform.
 10. The method of claim 9, wherein said movable platform is supported upon a frame.
 11. The method of claim 9, wherein said movable platform is raised or lowered to the feeder.
 12. The method of claim 9, wherein said movable platform is laterally moved to the feeder.
 13. The method of claim 9, wherein said movable platform is movable between an end of said conveyor and adjacent said feeder.
 14. The method of claim 1, further including sliding said mail off of said carrier onto said feeder with a transfer slide having an angled upper surface.
 15. A method for pre-processing mail delivered to at least one mail feeder having a conveyor from which mail is fed into a system, comprising: a) de-bundling mail at at least one preparation operator location; b) placing said de-bundled mail upon at least one mail carrier; and c) delivering said at least one mail carrier to at least one mail feeder via a delivery system that permits egress of a feed operator around a periphery of each of the at least one mail feeder.
 16. The method of claim 15, further including delivering carriers from a plurality of preparation operator locations to a common supply, and delivering said carriers from said common supply to a plurality of feed operator locations proximate respective mail feeders.
 17. The method of claim 15, wherein said delivering includes delivering said carriers via said delivery system along a path that includes a lateral component such that said carrier is moved, at least in part, laterally to the feeder.
 18. The method of claim 15, wherein said delivering includes delivering said carriers via said delivery system along a path that includes a generally vertical component such that said carrier is moved, at least in part, generally vertically to the feeder.
 19. The method of claim 15, wherein said delivery system includes a conveyor.
 20. The method of claim 15, wherein said delivery system includes a movable platform.
 21. The method of claim 15, wherein said delivery system includes a conveyor and a movable platform.
 22. The method of claim 21, wherein said movable platform is movable between a position adjacent said conveyor and a position adjacent said feeder.
 23. The method of claim 15, further including sliding said mail off of said carrier onto said feeder via an angled sliding surface.
 24. A method for pre-processing and delivering objects to an object-feeder, comprising: a) loading objects onto a plurality of carriers; b) conveying said carriers with a supply conveyor towards an object-feeder; c) transporting at least one of said carriers from said conveyor toward said feeder upon a reciprocated transporter; d) after transporting, transferring objects from said at least one carrier to said feeder; e) after transferring, placing said at least one carrier upon a return conveyor.
 25. The method of claim 24, wherein said platform is reciprocated at least partly in a generally vertical direction.
 26. The method of claim 24, wherein said platform is reciprocated at least partly in a generally horizontal direction.
 27. The method of claim 24, wherein said objects includes mail.
 28. A mail handling system, comprising: a) a feeder for feeding mail; b) a plurality of mail carriers; c) a transporter upon which at least one of said mail carriers can be placed; d) said transporter including a platform that is movable along a path from a location proximate said feeder to a location distal from said feeder so as to permit egress of a feed operator around a periphery of the feeder.
 29. The mail handling system of claim 28, wherein said path includes a lateral component such that said support is moved, at least in part, laterally to the feeder.
 30. The mail handling system of claim 28, wherein said path includes a generally vertical component such that said support is moved, at least in part, generally vertically to the feeder.
 31. An thin-object handling system, comprising: a) a feeder for feeding thin-objects; b) a plurality of carriers carrying a plurality of said thin-objects; c) a conveyor for conveying said carriers toward said feeder; d) a transporter arranged to transport at least one of said carriers from said conveyor toward said feeder, said transporter being movable to permit egress of a feed operator around a periphery of the feeder.
 32. The system of claim 31, wherein said thin objects include mail. 